Process for producing carboxylic acids and nitrogen containing intermediates from olefins

ABSTRACT

NITROPEROXYLNITRATE AND NITROPEROXYNITRATO ALKANOIC ACID COMPOUNDS AND METHOD OF PREPARING NITROPEROXY AND NITROKETONE COMPOUNDS FROM ALKENES OR ALKENOIC ACIDS COMPRISING CONTACTING AN ALKENE OR ALKENOIC ACID WITH A MIXTURE OF DINITROGEN TETROXIDE AND OXYGEN TO FORM THE NITROPEROXY COMPOUND AND CONTACTING THE NITROPEROXY COMPOUND WITH A DENITRATING AGENT TO FORM THE NITROKETONE.

PROCESS FOR PRODUCING CARBOXYLIC ACIDS AND NITROGEN CONTAINING INTERMEDI- ATES FROM OLEFINS Donald R. Lachowicz, Todd S. Simmons, and Kenneth L. Kreuz, Fishkill, N.Y., assignors to Texaco Inc., New York, N.Y., a corporation of Delaware No Drawing. Original application June 24, 1965, Ser. No. 466,816, now Patent No. 3,415,856, dated Dec. 10, 1968. Divided and this application May 31, 1968, Ser. No. 749,236 Int. Cl. C09f 7/00; C07c 73/10, 51/16, 45/04, 49/06 US. Cl. 260-4045 8 Claims ABSTRACT OF THE DISCLOSURE Nitroperoxylnitrate and nitroperoxynitrato alkanoic acid compounds and method of preparing nitroperoxy and nitroketone compounds from alkenes or alkenoic acids comprising contacting an alkene or alkenoic acid with a mixture of dinitrogen tetroxide and oxygen to form the nitroperoxy compound and contacting the nitroperoxy compound with a denitrating agent to form the nitroketone.

This is a division of Ser. No. 466,816, filed June 24, 1965, now US Pat. No. 3,415,856.

This invnetion relates to a combination process for producing alkanoic and alkandioic acids from alkenes and methyloic substituted alkenes (alkanoic acids). Futrther, it pertains to subcombination processes of converting olefins into the corresponding nitroperoxy (nitroalkylperoxy nitrate and peroxynitrato alkanoic acid) and nitroketone compounds. The invention is still further directed to nitro peroxy products as novel compounds formed as recoverable intermediates in the combination process of the invention.

In the past, many carboxylic acids were not generally available at low cost. For example, the odd numbered chain fatty acids were not available from natural sources and their manufacture from relatively expensive initial reactants was required. One prior means of producting carboxylic acids was by oxidizing the corresponding alcohol or by employing a Grignard synthesis, both of which require relatively costly starting materials. Further, the products obtained by these prior art methods contained impurities which were diflficult to remove thereby requiring complicated purification steps which further added to the cost of the product.

We have discovered and this constitutes our invention a relatively low cost method of producing saturated aliphatic carboxylic acids from low cost alkenes and alkenoic acids and further have devised method of preparing recoverable nitroperoxy and nitroketone intermediates wherein the nitroperoxy and nitroketone intermediates and carboxylic acid products are formed in a high degree of purity, that is, products which are free from minor impurities often occurring in their production which limit their usefulness. We have further isolated and identified for the first time certain novel classes of nitroperoxy compounds.

More specifically, the overall process and the subprocesses of the invention are defined in the following three stages.

FIRST STAGE The first stage of the overall process of the invention comprises simultaneously contacting an olefin having at least 6 carbons of the formula:

RCHCHR where R is alkyl (saturated aliphatic hydrocarbon) or polymethylenoic[tCH i COOH where x is an integer of United States Patent O 3,557,166 Patented Jan. 19, 1971 at least 1], R is hydrogen, alkyl, or polymethylenoic, and where as least one of said R and R groups is alkyl, with a mixture of dinitrogen tetroxide and oxygen to form a nitroperoxy intermediate of the general formula:

CONOz where R and R are as heretofore defined. It is to be noted that the nitro and peroxynitrato groups form on either olefinic carbon with the exception when the olefin group is terminal, the nitro group attaches itself to the terminal olefinic carbon. Therefore, when R is other than hydrogen the nitroperoxy and nitroketone intermediates are actually compound mixtures.

The reaction temperature employed is advantageously between about 40 and 20 C. Higher reaction temperatures tend to facilitate the decomposition of the peroxy nitrate product and at temperatures below the prescribed range the dinitrogen tetroxide would not function due to its inability to dissociate into monomeric nitrogen dioxide. The reactant mole ratio of olefin to dinitrogen tetroxide to oxygen is normally between about 110.5:1 and 1:15:30. However, the important aspect of the reactant ratio is that the moles of oxygen be at least equivalent and preferably in excess to the moles of dinitrogen tetroxide. If the ratio of N 0 is above that of oxygen another N0 group forms rather than the desired peroxy group. Excess oxygen even in excess of the stated range does not deleteriously affect the reaction. The reaction time is normally between about /2 and 10 hours although longer and shorter periods may be employed.

The formed nitroalkylperoxy nitrate or peroxynitrato alkanoic acid depending on the initial olefin reactant is recovered, if desired, by standard means, for example, via stripping volatiles.

It is to be noted that the nitrating agent, dinitrogen tetroxide, is actually an equilibrium mixture of dinitrogen tetroxide and nitrogen dioxide with the equilbrium being driven -to essentially dinitrogen tetroxide at 0 C. and essentially 100% nitrogen dioxide at C. Under advantageous conditions, the nitrating agent is normally introduced into the reaction system at a rate of between about 0.002 and 0.02 gram/min./gram olefin, however, the actual rate depends in large measure upon the rate of heat removal from the reaction system.

To promote contact of the reactants in the first stage, the reaction is desirably carried out under conditions of agitation in the presence of an inert liquid diluent, for example, inert liquids having a boiling point between about 30 and 100 C. such as n-hexane, n-heptane, carbon tetrachloride and diethylether.

The olefinic reactant employed should be of at least 6 carbons and preferably less than about 55 carbon atoms although higher molecular weight olefins may be utilized. The contemplated olefinic materials can be derived from many sources such as wax cracking and olefin polymerization. Examples of the olefinic reactants contemplated are l-dodecane, l-octene, l-hexene, l-octadecene, 4 tridecene, 10 eicosene and C H COOH alkenoic acids wherein n is an integer of at least 5 and preferably less than about 54 carbons such as 9-octadec'enoic (olgic acid), 10-pentadecanoic acid and 4-dodecene-2-oic act The oxygen employed may be in the pure form or in the diluted form such as air or in admixture with inert gases such as nitrogen and argon. Under advantageous conditions the oxygen is introduced into the reaction system at a rate of between about 5 and 18 mls./min./ gram olefin.

Examples of the intermediate nitroalkylperoxy nitrate and peroxynitrato alkenoic acid products are 1-nitro-2- dodecylperoxy, 1 -nitro 2-octylperoxy nitrate, 1-nitro-2- octadecylperoxy nitrate, 1-nitro-2-hexylperoxy nitrate, mixture of -nitro-4-tridecylperoxy nitrate and 4-nitro-5- tridecylperoxy nitrate, mixture of ll-nitro-lO-eicosylperoxy nitrate and -nitro-l l-eicosylperoxy nitrate, mixture of l0-nitro-9-peroxynitrato octadecanoic acid and 9-nitrolO-peroxynitrato octadecanoic acid, mixture of lO-nitroll-peroxynitrato pentadecanoic acid and ll-nitro-lO-peroxynitrato pentadecanoic acid, mixture of l0-nitro-1l-peroxynitrato octadecanoic acid and l1-nitro-10-peroxynitrato-octadecanoic acid, mixture of 4-nitro-5-peroxy nitrato-dodecan-Z-oic acid and 5-nitro-4-peroxynitrato dodecan-Z-oic acid.

SECOND STAGE The nitroalkylperoxy nitrate or nitratoperoxy alkanoic acid of at least 6 carbons of the formula:

where R and R are as heretofore defined recovered from the first stage is contacted with a denitrating agent selected from the group consisting of where R R R and R are alkyl of from 1 to 5 carbons and R R and R are hydrogen or alkyl of from 1 to 5 carbons. The reactant contacting is conducted, preferably with agitation, at a temperature between about 60 and 70 C. in a mole ratio of denitrating agent to peroxy compound of at least about 1:1 preferably less than about :1 to forma nitroketone of the formula:

where R and R are as heretofore defined. The reaction of the second stage is more or less instantaneous after addition of reactants. The particular mode of bringing the eractants together depends on many things such as molecular weight of reactants and reactivity of the peroxy material. Normally, with the more reactive peroxy materials, the contacting of reactants is accomplished by slow addition of the peroxy intermediate to the denitrating agent.

The nitroketone intermediate product can be recovered by standard recovery processes, for example, via filtration of the solid intermediate after the addition of the reaction mixture to water or via distillation.

Normally, inert diluent is not employed in the second stage of the overall process if one of the reactants is in liquid form. However, if both reactants are in the solid state, then the facilitate interaction inert liquid diluent is employed, for example, inert liquid diluent having a boiling point between about and 100 C. such as pentane, hexane, carbon tetrachloride and diethylether. Agitation of the reaction mixture is also a preferred condition.

Specific examples of the denitrating agents contemplated herein are dimethylformamide, diethylformamide, dimethylacetamide, dimethyl sulfoxide, diethylsulfoxide, tetramethylurea and tetraethylurea.

Specific examples of the nitroketone products in the second stage process are l-nitro-Z-dodecanone, l-nitro-Z- octanone, 1-nitro-2-octadecanone, l-nitro 2 hexanone, mixture of 4-nitro-5-tridecanone and 5-nitro-4-tridecanone, mixture of 11-nitro-10-eicosanone and 10-nitro-11- eicocanone, mixture of 10-nitro-9-ketone-octadecanoic acid and 9-nitro-10-keto-octadecanoic acid, mixture of 10-nitro-ll-keto-pentadecanoic acid and 11-nit1'o-10-keto pentadecanoic acid, mixture of 4-nitro-5-keto-dodecan- 2-oic acid and S-nitro-4-keto-dodecan-Z-oic acid.

4 THIRD STAGE In the third stage of the process the nitroketone having at least 6 carbons of the formula:

where R and R are as heretofore defined recovered from second stage is contacted with water in the presence of an acid member selected from the group consisting of mineral acid, hydrocarbon sulfonic acid and halo acetic acid having a dissociation constant in excess of 10- at a temperature of between about 0 C. and 150 C. in a mole ratio of nitroketone to acid member of between about 111 and 1:10 and in a mole ratio of nitroketone to water of at least about 1:2 to form a carboxylic acid of the general formula:

RCOOH AND R COOH where R and R are as heretofore defined. This third stage of the reaction is normally conducted for a period in the range of 15 minutes to several hours. However, the actual reaction time will be dependent in large measure on the kind and strength of the acid member employed. Under preferred conditions, the reaction mixture is agitated in order to facilitate contact between the reactants. Further, if both the acid and ketone are of the solid nature, in order to afford better reactant contact, inert liquid diluent is advantageously employed, for example, inert liquid diluent having a boiling point between about and 150 C. such as acetic acid.

The water contact in the third stage is normally accom plished by first forming the final nitroketone-acid reaction mixture and then contacting with a excess of Water, e.g., pouring said reaction mixture into a stoichiometric excess of cold water The carboxylic acid product is recovered by standard means such as by filtration or extracting the formed carboxylic acid, e.g., with ether, followed by stripping ofl? the extractant from the extract solution to leave the carboxylic acid as residue.

Examples of the final carboxylic acid products contemplated herein are formic acid, undecanoic acid, heptanoic acid, pentanoic acid, heptadecanoic acid, butanoic acid, nonanoic acid, decanoic acid, azelaic acid, undeadioic acid and glutaric acid.

Specific examples of the acid catalyst contemplated in Stage III are sulfuric acid, phosphoric acid, nitric acid, trichloroacetic acid, methane sulfonic acid, and ethane sulfonic acid. The acids employed are advantageously of an acid strength in respect to aqueous dilution of at least about wt. percent of the concentrated state.

The combination process and subcombination processes (Stages I, II, III) of the invention may be further defined by the following equations utilizing dodecene, dimethylformamide and sulfuric acid as the example reactants:

CmHgr-CH-CIDNO 2 O ONO? O 0 II (III) CwHnCCHzNO: I'IQSO4 21120 0 11 00011 1100011 NIIgOlLlIgSO; The following examples further illustrate the invention but are not to be construed as limitations thereof.

EXAMPLE I This example illustrates the first stage of the overall process, namely, the preparation of the intermediate peroxy compounds from olefins.

Through a mixture of mls. of l-dodecene and 60 mls. of n-hexane maintained at 0 C. there was bubbled oxygen at a rate of 56.5 mls./min. together with the simultaneous introduction of about 2.2 grams of dinitrogen tetroxide over about a 4 hour period. The volatiles in the final reaction mixture were removed under reduced pressure and the residual product was identified by infrared and nuclear magnetic resonance spectroscopy as 1-nitro-2-dodecylperoxy nitrate.

EXAMPLE II This example illustrates the second stage of the overall process, namely, the conversion of the peroxy compound of Example I into the corresponding nitroketone.

In an amount of 7.22 grams (0.023 mole) 1-nitro-2- dodecylperoxy nitrate of Example I was added to 25 mls. of dimethylformamide with agitation at 2127 C. and the mixture was immediately added to water. The resultant aqueous mixture was filtered and a solid product weighing 4.68 grams was recovered. The solid product was identified as l-nitro-2-dodecanone representing a yield of 90 mole percent based on the initial dodecene reactant.

EXAMPLE III This example illustrates the third stage of the overall process, namely, the conversion of the nitroketone of Example II to the corresponding carboxylic acid.

The 4.68 grams of l-nitro-Z-dodecanone prepared in Example II there was added 50 mls. of concentrated sulfuric acid and the mixture was heated with stirring for minutes and then added to a stoichiometric excess of water. A solid product weighing 2.65 grams was recovered by extraction of the resultant aqueous mixture with ether followed by ether evaporation leaving said product as residue. The residual product was identified as undecanoic acid in a yield of 70 mole percent based on the initial dodecene reactant.

EXAMPLE IV This example further illustrates the overall process and subprocesses of the invention.

To a magnetically stirred flask there was added 5.4 grams of oleic acid and 60 mls. of n-hexane. The mixture was cooled and maintained at 0 C. and simultaneously bubbled therethrough were oxygen at a rate of 56.5 mls./ min. and 1.4 mls. of dinitrogen tetroxide. When all the N 0 had been added, the solvent and excess N0 were removed by vacuum and the residual product was identified as a mixture of 9-nitro-10peroxynitrato octadecanoic acid and 10-nitro-9-peroxynitrato octadecanoic acid.

The above residual product was cooled to about C. and mls. of dimethylformamide were added thereto and the resultant mixture was stirred for about 0.5 hour in a temperature range between -20 and 16 C. The stirred mixture was then poured into 150 mls. of H 0 and filtered. The filtered solids were water washed and weighed 6.5 grams. They were identified essentially as a mixture of 9-nitro-10-keto octadecanoic and 10-nitro-9-octadecanoic acid representing a yield of 98.5%. This nitroketone product was further purified by successive extractions with water, carbon tetrachloride and ether.

To mls. of glacial acetic acid there was added 1 gram of the above purified nitroketone mixture and 10 mls. of HNO The resultant mixture was stirred and heated 3 hours at 110 C. and then poured into cold water (large stoichiometer excess). The resultant aqueous mixture was extracted with ether and the ether extract solution was subjected to distillation to remove the ether leaving a yellowish oil. The yellowish oil was subjected to fractional distillation under reduced pressure and 0.3 gram of pelargonic acid and 0.5 gram of azelaic acid were recovered. This represented a yield of 60 mole percent for pelargonic and 90 mole percent for azelaic based on the nitroketone reactant.

6 We claim: 1. A method of preparing a peroxy compound having at least 6' carbons of the formula:

OONOz R- H-OHR l loz where R is alkyl containing up to 18 carbons or -CHfi COOH where x is an integer of from 2 to 16, R is hydrogen, alkyl containing up to 18 carbons, or tcHmcooH where x is as heretofore defined and at least one of said R and R is said alkyl and said R and R containing a total of up to 18 carbons comprising simultaneously contacting an olefin having 6 to 20 carbons of the formula RC H=CH-R where R and R are heretofore defined and where at least one of said R and R is said alkyl with dinitrogen tetroxide and oxygen at a temperature between about 40 and 20 C. in a mole ratio of olefin to dinitrogen tetroxide to oxtygen of between about 1:0.5z1 and 1:15:30 to form said peroxy compound.

2. A method in accordance with claim 1 wherein said olefin is l-dodecene, and wherein said peroxy compound is 1-nitro-2-dodecylperoxy nitrate.

3. A method in accordance with claim 1 wherein said olefin is oleic acid, and wherein said peroxy compound is a mixture of 9-nitro-10-peroxynitrato octadacanoic acid and 10-nitro-9-peroxynitrato octadecanoic acid.

4. A method of preparing a nitroketon of at least 6 carbon atoms of the formula:

Rii-OHR where R is alkyl containing up to 18 carbons or +CH -I COOH where x is an integer of from 2 to 16, R is hydrogen, alkyl containing up to 18 carbons or {CHfi COOI-I where x is as heretofore defined and at least one of said R and R is said alkyl and said R and R containing a total of up to 18 carbons comprising:

(1) simultaneously contacting an olefin having 6 to 20 carbons of the formula RCH=CH-R where R and R are as heretofore defined and 'where at least one of said R and R is said alkyl, with dinitrogen tetroxide and oxygen at a temperature between about 40 and 20 C. in a mole ratio of olefin to dinitrogen tetroxide to oxygen of between about 1:0.5z1 and 1:15:30 to form a peroxy compound of the formula:

OONOz where R and R are as heretofore defined,

R2\ R4\ O /NC=O /NC-R and R -sR Rs R:

where R R R and R are alkyl of from 1 to 5 carbons and R R and R are hydrogen or alkyl of from 1 to 5 carbons at a temperature between about -60 and C. in a mole ratio of said denitrating agent to said peroxy compound of between about 1:1 and 20:1 to form said nitroketone. 5. A method in accordance with claim 4 wherein said nltroketone is l-nitro-Z-dodecanone, said olefin is 1- dodecene, said peroxy compound is 1-nitro-2-dodecylperoxy nitrate, said denitrating agent is dimethylformamide and wherein said olefin-dinitrogen tetroxide-oxygen contact is conducted in the presence of n-hexane.

6. A method in accordance with claim 4 wherein said nitroketone is a mixture of 9-nitro 10-ket0-0ctadecanoic acid and 10-nitro-9-keto-octadecanoic acid, olefin is oleic acid, said peroxy compound is a mixture of 9-nitro-10- peroxy-nitrato oetadecanoic acid and 10-nitr0-9-peroxynitrato octadecanoic acid, said denitrating agent is dimethylformamide, and wherein said olefin-dinitrogen tetroxide-oxygen contact is conducted in the presence of n-hexane.

7. Mixture of 9-nitro-IO-peroxynitrato octadecanoic and -10-nitr0-9-per0xynitrato octadecanoic acid.

8. A peroxy compound having at least 6 carbons of the formula:

where R is alkyl containing up to 18 carbons or -CHfi COOH where x is an integer of from 2 to 16, R is hydrogen, alkyl containing up to 18 carbons or &CH COOH where x is as heretofore defined and at least one of said R and R is said alkyl and said R and R containing a total of up to 18 carbons.

References Cited LEWIS GOTTS, Primary Examiner G. HOLLRAH, Assistant Examiner .U.S. Cl. X.R. 

